Battery Testing and Hazard Analysis

Lithium-ion battery production, maintenance, installation, and transportation are covered by a number of safety requirements and standards. Yet the ongoing incidents including fires and explosions with batteries confirm that the current regulatory framework is insufficient alone for predicting the most likely reasons for failure.

Battery testing and hazard analysis can provide additional information to help reduce these incidents. In addition to providing complete safety and risk management services for the process safety industry, ioMosaic offers global expertise with lithium-ion battery safety regulations to help you minimize your exposure to fire, injury, property damage, and litigation.

Understanding Battery Safety

Lithium-ion batteries are being utilized in more and more applications; from consumer electronics to automobiles, airplanes, and even energy storage systems. Failure can result in both performance and safety concerns such as cell capacity reduction and possible separator defects leading to fires. The possibility of cell failure is difficult to completely prevent, however with proper testing, tools, and expertise we help our clients mitigate and reduce the risk.


Battery Hazards and Consequences


Battery Hazard Analysis Services

ioMosaic pioneered many of the current techniques for conducting a hazard analysis. We understand and employ best practice techniques, including preliminary or inherent hazard analysis, hazard and operability (HAZOP) studies, and failure modes and effects analyses (FMEA) of single lithium-ion batteries and battery energy storage systems (BESS). Each scenario's impact and frequency are evaluated by our process. We also help you identify safeguards and other mitigation strategies to reduce the risk to your installation following a Battery Hazard Analysis (BHA).

  • Cell design review
  • Manufacturing quality review
  • Onsite manufacturing process and quality auditing
  • Cell and battery pack tear down and assessment
  • Battery failure investigation

Battery Testing Capabilities

Our exclusive partner ioKinetic has many years of experience testing the variety of battery chemistries available and all popular battery types. A Calorimeter can be used to measure the safety of batteries by simulating both normal and worst-case operating conditions safely under laboratory conditions. These techniques include differential scanning calorimetry, thermogravimetric analysis, explosion severity, and accelerating rate calorimetry.

Our ISO accredited, ultramodern testing facility offers the following lab tests (but not limited to):

  • Adiabatic heat-wait-search
  • Overheating
  • External short circuit
  • Nail penetration and crush
  • Heat capacity measurements
  • Overcharging
  • Pressure measurement
  • Gas collection and analysis


Calorimeter instrument


Please Note: Maximum capacity tested: 150 Ah. Pressure test limits are 4 bar and 25 Ah capacity. The chamber size is 25 cm in diameter and 60 cm in depth. Maximum testing limits may vary depending on battery chemistry and format; please contact ioMosaic for more information.


Sampling of Battery Failure Standards

Test Type Examples


Pass Criteria 
SAE J2462 Used in electric and
hybrid automobiles.

Nail Penetration
Thermal Stability 

55°C Multiple
No N/A
 UL 9540A Used in solar or wind energy systems
and energy storage systems.
Overheating Ambient Central No No fire or explosion propagating from the battery under test.
IEC 62619 Used in industrial applications;
more specifically considerations for internal short circuits.
Nail Penetration
Maximum Use Temperature
or 25°C
Multiple Yes No fire or battery case rupture.
 UL 1973 Used in light
electric rail.
Nail Penetration
Maximum Use Temperature
or 25°C
Potential for Multiple Yes No fire or explosion propagating from the battery under test DUT.
KMVSS 18-2
& 3 (Korea)
Requirement for HV batteries systems of electric vehicles. Heat Exposure
80°C for Heat Exposure
25°C for Overcharge
Potential for Multiple Yes There must be no ignition or explosion.


Hazard Analysis Tools

Our software Process Safety Office® PHAGlobal® is the most useful and cost-effective PHA/DHA tool on the market. The process hazard assessment documentation software simplifies the recording of findings and tracking follow-up from PHAs. It also eliminates the need for any special application software when working with the results. PHAGlobal® delivers professional, branded reports and make it easier to comply with codes and standards, such as OSHA PSM, EPA RMP and NFPA, that require PHAs.


Interested In Learning More?

We understand the safety and risk processes needed or adhered to worldwide, and we deliver practical, locally compliant solutions to safety and risk challenges facing our clients. Call us today at 1.844.ioMosaic or fill out our online form. We would love to hear from you.

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ioKinetic Battery Testing

Our exclusive partner ioKinetic has many years of experience testing the variety of battery chemistries available and all popular battery types. Their experienced professionals can help you define what you need, conduct the testing, interpret the data, and conduct detailed analysis. Learn more.

Learn More About PHAGlobal®

Remember, OSHA regulations mandate that a PHA or DHA needs to occur every 5 years or sooner if a MOC occurs. Get your team the tools they need to conduct a quality risk analysis now.

Request a Software Quote

Ready to drive workflow efficiency at your organization? Call us at 1.844.ioMosaic or fill out our online form.

Overpressure Protection of Battery Energy Storage Systems (BESS) White Paper

Overpressure Protection of Battery Energy Storage Systems (BESS)


Read this white paper for an exploration of the mechanics of deflagrations that can occur during a thermal runaway event in a BESS and methods for sizing deflagration vents to protect against such explosions in elongated geometries.


How We Can Help You

ioMosaic pioneered many of the current risk assessment techniques for processes that handle hazardous chemicals.

Our experts support every aspect to ensure that your facility runs safely and efficiently.

Expertise to help you minimize your exposure to fire, injury, property damage, and litigation.

Integrating best practices with cost-effective solutions to address program deficiencies.

Helping manage risk with facility siting studies, assessments and recommendations.

Senior knowledgeable engineers facilitate PHAs or DHAs in nearly all sectors of the process and processing industries.

Decades of experience leading incident investigations for process industry companies.

We prepare expert opinion reports and provide expert testimony for process incident cases.

Experienced engineers who have performed LOPAs on a wide range of facilities and terminals.

Our experts are at the forefront of pipeline Process Safety Management proficiency.

Offering a comprehensive range of safety, technology and risk management training.

Proven track record of performing QRAs for facilities, pipelines and transportation routes.

Well versed in assisting global companies with their sustainability reporting communications.

Decades of experience mitigating hazards for the chemical and pharmaceutical industries.